All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission ofQuality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has beentaken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make suchchanges to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.Illustrations and photographs in this publication are intended for reference use only and may not depict actual modelcomponent parts.
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LIST OF ABBREVIATIONSA ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)AC alternating current min minute(s)ATDC after top dead center N newton(s)BBDC before bottom dead center Pa pascal(s)BDC bottom dead center PS horsepowerBTDC before top dead center psi pound(s) per square inch�C degree(s) Celcius r revolutionDC direct current rpm revolution(s) per minuteF farad(s) TDC top dead center�F degree(s) Fahrenheit TIR total indicator readingft foot, feet V volt(s)g gram(s) W watt(s)h hour(s) ohm(s)L liter(s)
Read OWNER’S MANUAL before operating.
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EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated exhaust emission control systems (EM) incompliance with applicable regulations of the United States Environmental Protection Agency and California Air ResourcesBoard.
1. Exhaust Emission Control SystemThe exhaust emission control system applied to this engine consists of a carburetor and an ignition
system having optimum ignition timing characteristics.The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel
economy with a suitable air cleaner and exhaust system.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or renderinginoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element ofdesign incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimatepurchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed orrendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:Do not tamper with the original emission related part:
• Carburetor and internal parts• Spark plugs• Magnet or electronic ignition system• Fuel filter• Air cleaner elements
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Foreword
This manual is designed primarily for use by trainedmechanics in a properly equipped shop. However, itcontains enough detail and information to make it usefulto the owner who desires to perform his own basicmaintenance anbd repair work. A basic knowledgeof mechanics, the proper use of tools, and workshopprocedures must be understood in order to carry outmaintenance and repair satisfactorily. Whenever theowner has insufficient experience or has doubts as to hisability to do the work, all adjustments, maintenance, andrepair should be carried out only by qualified mechanics.
This manual covers models: KBL23A, KBH26A,KBL26A, KBH33A, KBL33A, KBH34A, KBL34A, KBH43A,KBL43A, KBH48A and KBL48A. As for safety information,specifications, exploded view, assembly and preparation,operating instructions, and periodic maintenance; thismanual does not mention them as you can depend upontheir respective owner’s manuals and parts catalogues totell you the details.
In order to perform the work efficiently and to avoidcostly mistakes, read the text, thoroughly familiarizeyourself with the procedures before stating work, and thendo the work carefully in a clean area. Whenever specialtools or equipment are specified, do not use makeshifttools or equipment. Precision measurements can only bemade if the proper instruments are used, and the use ofsubstitute tools may adversely affect safe operation.
To get the longest life out of your equipement.
• Follow the Periodic Maintenance Chart in their respec-tive owner’s manuals.
• Be alert for problems and non-scheduled maintenance.
• Use proper tools and genuine Kawasaki engine parts.Genuide parts provided as spare parts are listed in theParts Catalog.
• Follow the procedures in this manual carefully. Don’ttake shortcuts.
• Remember to keep complete records of maintenanceand repair with dates and any new parts installed.
How to Use This ManualWhenever you see these WARNING and CAUTION
symbols, heed their instructions! Always follow safeoperating and maintenance practices.
This warning symbol identifies special instruc-tions or procedures which, if not correctly fol-lowed, could result in personal injury, or loss oflife.
CAUTION
This caution symbol identifies special instruc-tions or procedures which, if not strictly ob-served, could result in damage to or destructionof equipment.
This manual contains four more symbols (in addition toWARNING and CAUTION) which will help you distinguishdifferent types of information.
NOTE
This note symbol indicates points of particular in-terest for more efficient and convenient operation.
• Indicates a procedural step or work to be done. Indicates a procedural sub-step or how to do the work
of the procedural step it follows. It also precedes thetext of a WARNING, CAUTION, or NOTE.Indicates a conditional step or what action to take basedon the results of the test or inspection in the proceduralstep or sub-step it follows.
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1-2 GENERAL INFORMATIONBefore Servicing
Before starting to service the engine, careful read the applicable section to eliminate unnecessary work. Photographs,diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless,even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
Especially note the following:(1) Dirt
Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts will workas an abrasive and shorten the life of the engine. For the same reason, before installing a new part, clean off anydust or metal filings.
(2) Tightening SequenceGenerally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causinggas or oil leakage. Conversely, when loosening the bolts, nuts, or screws, first loosen all of them by about a quarterof a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts,nuts, or screws must be tightened in the order and method indicated.
(3) TorqueWhen torque values are given in this Service Manual, use them. Either too little or too much torque may lead to
serious damage. Use a good quality, reliable torque wrench.(4) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especiallydifficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, taplightly using a rubber, wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal ofscrews held by a locking agent) in order to avoid damaging the heads.
(5) EdgesWatch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves
or a piece of thick cloth when lifting the engine or turning it over.(6) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in NorthAmerica is Standard solvent (generic name). Always follow manufacturer and container directions regarding the useof any solvent.
(7) Gasket, O-RingDo not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be
free of foreign matter and perfectly smooth to avoid oil or compression leaks.(8) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Applysparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).
(9) PressA part installed using a press or driver, such as a journal, should first be coated with oil on its outer or inner
circumference so that it will go into place smoothly.(10) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver.This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ballbearing until it stops at the stop in the hole or on the shaft.
(11) Oil Seal and Grease SealReplace any oil or grease seals that were removed with new ones, as removal generally damages seals.When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be
pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is evenwith the end of the hole.
(12) Seal GuideA seal guide is require for certain oil or grease seals during installation to avoid damage to the seal lips. Before
a shaft passes through a seal, apply a little oil, preferable high temperature grease on the lips to reduce rubber tometal friction.
(13) Circlip, Retaining RingReplace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them.
When installing circlips and retaining rings, take care to compress or expand them only enough to install them andno more.
(14) Cotter PinReplace any cotter pins that were removed with new ones, as removal deforms and breaks them.
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GENERAL INFORMATION 1-3Before Servicing
(15) LubricationEngine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have
an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to anyrubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated greasehas lost its lubricative quality and may contain abrasive foreign particles.
Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applicationsand may be harmful if used in an application for which they are not intended. This manual makes reference tomolybdenum disulfide grease (MoS2) in the assembly of certain engine and chassis parts. Always check manufacturerrecommendations before using such special lubricants.
(16) Replacement PartsWhen there is a replacement instruction, replace these parts with new ones every time they are removed. These
replacement parts will be damaged or lose their original function once removed.(17) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. Ifthere is any doubt as to the condition of them, replace them with new ones.
(18) SpecificationsSpecification terms are defined as follows:"Standards" show dimensions or performances which brand-new parts or systems have."Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.
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1-4 GENERAL INFORMATIONIdling Speed
Idling Speed Adjustment• Start the engine and leave it running at idling speed to warm it up
thoroughly.
• If the engine stops while idling, turn the throttle stop screw (A)clockwise until the cutting head or the cutting blade begins to rotate.Then back off one half turn. The cutting head or the cutting blademust not rotate.
• If the cutting head or the cutting blade rotates when the engineis idling, turn the throttle stop screw (A) counterclockwise until thecutting head or the cutting blade stops rotating and then turn thethrottle stop screw (A) another one half turn.
KBL23A/KB 26A/KB 34A
KB 33A
KBH43A/KBH48A
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GENERAL INFORMATION 1-5General Specifications
Model KBL23A KBH26A KBL26AHandle type Loop handle Double handles Loop handleEngie Type Forced air cooled 2-stroke, horizontal shaft gasoline engine
Carburetor Diaphragm typeIgnition Solid state ignitionSpark plug NGK BPMR6AStarter Recoil starterClutch Automatic centrifugal type
mm (in.) �54 (2.1)Fuel Mixing ratio Regular unleaded gasoline 50:1 2-stroke engine oil
Tank capacity litre 0.5 0.6 0.6Drive shaft Cutter Nylon stringasembly & gear Dia. of string mm (in.) �2.4 (0.095)housing Bearing of shaft 5 plane
Rotation CounterclockwiseLubrication High quality lithium greaseDrive shaft dia. mm (in.) �6 (0.24)Drive shaft metarial High tensile steelReduction ratio 14 : 19Guard Plastic guard on the pipe assembly
**”Weight”: The unit without cutting attachment and shoulder harness, empty fuel tank.
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1-6 GENERAL INFORMATIONGeneral Specifications
Model KBH33A KBL33A KBH34A KBL34AHandle type Double Loop Double Loop
handles handle handles handleEngine Type Forced air cooled 2-stroke, horizontal shaft gasoline engine
Carburetor Diaphragm typeIgnition Solid state ignitionSpark plug NGK BMR6AStarter Recoil starterClutch drum dia. Automatic centrifugal type
mm (in.) �78 (3.1)Fuel Mixing ratio Regular unleaded gaoline 50:1 2-stroke engine oil
Tank capacity litre 0.8 0.8 0.8 0.8Drive shaft ass’y Cutter Nylon cord& gear housing Dia. of cord mm (in.) �2.4 (0.095)
Bearing of shaft 5 planeRotation CounterclockwiseLubrication High quality lithium greaseDrive shaft dia. mm (in.) �8 (0.31)Drive shaft material High tensile steelReduction ratio 17 : 21Guard Plastic guard on the pipe ass’y
**”Weight”: The unit without cutting attachment and shoulder harness, empty fuel tank.
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GENERAL INFORMATION 1-7General Specifications
Model KBH43A KBL43A KBH48A KBL48AHandle type Double Loop Double Loop
handles handle handles handleEngine Type Forced air cooled 2-stroke, horizontal shaft gasoline engine
Carburetor Diaphragm typeIgnition Solid state ignitionSpark plug NGK BMR6AStarter Recoil starterClutch drum dia. Automatic centrifugal type
mm (in.) �78 (3.1)Fuel Mixing ratio Regular unleaded gaoline 50:1 2-stroke engine oil
Tank capacity litre 1.0 1.0 1.0 1.0Drive shaft ass’y Cutter Nylon cord& gear housing Dia. of cord mm (in.) �2.4 (0.095)
Bearing of shaft 5 planeRotation CounterclockwiseLubrication High quality lithium greaseDrive shaft dia. mm (in.) �8 (0.31)Drive shaft material High tensile steelReduction ratio 17 : 21Guard Plastic guard on the pipe ass’y
**”Weight”: The unit without cutting attachment and shoulder harness, empty fuel tank.
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1-8 GENERAL INFORMATIONPeriodic Maintenance Chart
Accidental engine starting can cause injury.Always remove the spark plug cap before servicing the engine to prevent accidental starting.
Interval
Maintenance Daily First Every Every Every
20 hours 20 hours 50 hours 100 hours
Check and replenish fuel •Check for fuel leakage •Check bolts, nuts and screws for looseness and loss •Check throttle lever operation •Check engine switch operation •Check guard assembly condition •Check hook of shoulder harness condition •Clean fuel filter •
* Clean air filter element •Tighten bolts, nuts and screws • •Clean spark plug and adjust electrode gap •
* Remove dust and dirt from cylinder fins •Remove carbon deposits on piston head •
and inside cylinder
Remove carbon deposits in the exhaust •pipe of muffler
Check gear case assembly lubrication •Check drive shaft lubricaion •Check the sliding portion of crankshaft, •
connecting rod etc.
Fuel tube It is recommended to replace every 3 years.
NOTE The service intervals indicated are to be used as a guide. “*”Service to be performed more frequently as
necessary by operating condition.
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GENERAL INFORMATION 1-9Tightening Torque
The following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanentlocking agent or requid gasket.
Letters used in the following “Tightening Torque” table mean.LA: Apply a non-permanent locking agent to the threads.LG: Apply a liquid gasket to the sealing surfaces.
about 4000 rpm at 4.0N�m (0.4 kg�m), of dragtorque
about 3800 rpm at 4.0 N�m(0.4 kg�m) of drag torque
about 3500 rpm at 4.0N�m (0.4 kg�m) of drag
torqueMax. engine speed (rpm) Different depending on matching machineIdling speed (rpm) 3000 ± 200 rpmIgnition coil air-gap 0.3 to 0.5 mm 0.4 to 0.5mm 0.3 to 0.5 mm
(0.011 to 0.019 in.) (0.015 to (0.011 to 0.019 in.)0.019 in.)
ignition timing 25� B.T.D.C. @7000 rpmGear ratio 14:19 17:21Jet needle clip location – 2/3 - 2/3Main adjust screw turning out – 1 1/2 ± 1/2 - 1 1/2 ± 1/2Gear case grease about 8 to 10 grams about 13 to 17 gramscapacity (full case)
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Cutting Head .................................................................................................................................................................... 2-12Cutting Head Installation...........................................................................................................................................2-12
Cutting Head except Australian Model.............................................................................................................................2-13Disassembly .............................................................................................................................................................. 2-13Reassembly...............................................................................................................................................................2-13
Cutting Head — Australian Model....................................................................................................................................2-14Disassembly .............................................................................................................................................................. 2-14Reassembly...............................................................................................................................................................2-14Operation Check........................................................................................................................................................2-16Gear Case Service....................................................................................................................................................2-16Drive Shaft Service....................................................................................................................................................2-17
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2-2 POWER TRAINComplete Engine
Complete Engine Removal — KBL23A/KB 26A/KB 34AThe power train has been designed to have friction enough between
the clutch housing and the guard tube so that it can keep the guard tubefrom turning and coming off. Thus it is almost impossible to remove notonly the ball bearings but the clutch drum.
• Unscrew the mounting screw (A) to remove the carburetor cover (B).
• Remove the cable-end nipple (A) out of the throttle valve terminal (B).
• Release the cable adjuster locknut (C) to remove the cable adjuster(D) out of the bracket (E).
• Release the guard tube clamp screw (A) and the lead wire connectors(B, C).
• Pull the complete engine out of the guard tube (A) and withdraw thedrive shaft (B).
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It is very hard to remove the combination damper out of the clutchhousing (in order for friction to make the engine kept from turningrelatively to the guard tube), being almost impossible to remove alsothe clutch drum.
• Snap the joint case (A) open.
• Detouch the cable-end nipple (B) out of the cable-end stub (C).
• Release the locknut (D) to remove the mid-adjuster (E) out of the jointcase (A) together with the throttle cable (F).
• Remove the set screw (A) keeping the engine from turning.
• Release the guard tube clamp screw (B) just enough to withdraw thecomplete engine out of the guard tube.
• Unfasten the stop switch lead-connectors (A, B), and untie theclamp(C).
• Pull the complete engine out of the guard tube (A).
• Withdraw the drive shaft (B) from the guard tube (A).
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2-4 POWER TRAINComplete Engine
Complete Engine Installation — KBL23A/KB 26A• Installation is the reverse of removal:
Note the following points: Have the end of the guard tube (A) coming home to the bottom of
the clutch housing (B). Have the spline-end of the drive shaft (C) meshing with that of the
clutch drum’s stub (D).
Tighten the clamp screw (C) to bring imaginary planes (A-A and B-B)into line (See Tightening Torque Table).
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POWER TRAIN 2-5Complete Engine
Complete Engine Installation — KB 33A/KB 34A/KB 43A/KB 48A• Installation is the reverse of removal.
Note the following points: Have the end of the guard tube (A) coming home to the bottom of
the clutch housing (B). Have the spline-end of the drive shaft (C) meshing with that of the
clutch drum’s stub (D).
Align the hole (A) of the clutch housing (C) with that of the guard tubeto tighten the alignment screw (B) and then tighten the clamp screw(D) to the specified torque.
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2-6 POWER TRAINComplete Engine
Throttle Cable Free Play Adjustment — KB 33A/KB 43A/KB 48A• After the throttle cable (A) was connected in the coupler (B), place the
throttle lever at its idle position to adjust the nut (C) in order that theend (A) of the throttle outer cable can come to the position specifiedin the figure with the cable-related level.
• Lock the adjusting nut (C) by turning the locking nut (D).
Throttle Cable Free Play Adjustment — KBL23A/KB 26A/KB 34A• After the throttle cable (A) was connected to the carburetor, place the
throttle lever at its idle position to adjust free play of the throttle cable(A) to about 1 mm (0.04 in.) long by turning the adjuster (B) with theloop handle installed in place.
• Tighten the locknut (C) to keep the adjuster (B) from loosening.
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POWER TRAIN 2-7Gear Case
Removal• Remove the alignment screw (A) keeping the complete gear case
from turning.
• Release the clamp screw (B) all the way.
• Pull the complete gear case (C) out of the guard tube (D).
• Release its clamp screw to remove the gear case cover (E).
KBL23A/KB 26A
Installation• Installation is the reverse of removal.
• Align a hole (A) of the gear case (C) with that of the drive tube (D)to tighten the alignment screw (A) and then tighten the clamp screw(B) to the specified torque.
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2-8 POWER TRAINGear Case
Disassembly — KBL23A/KB 26A• Remove the circlips (A, B) out of their respective grooves. Heat the complete gear case to about 110�C to 140�C (230�F to
280�F) on a heating plate to make bearing removal easy.
Be careful with the hot gear case and relative parts. They maybe hot enough to burn you severely.
• Pull the drive pinion (C) off the gear case (D) together with the ballbearing (E) and then pull the cutting tool shaft (F) off the case (D)together with the ball bearing (G) and the bevel gear (H).
• Remove the circlip (K) to press the drive pinion (C) out of the ballbearing (E).
• Hit the gear case against a wooden block to get the ball bearing (J)falling out of the gear case (D).
• Remove the circlip (K) out of the pinion (C) to separate the ball bearing(E) from the drive pinion (C).
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POWER TRAIN 2-9Gear Case
Disassembly — KB 33A/KB 34A/KB 43A/KB 48A• Remove the circlips (A) out of the cutting tool shaft (B).
• Pry out the oil seal (C).
• Remove the circlips (D, E) out of respective grooves. Heat the complete gear case to about 110�C to 140�C (230�F to
280�F) on a heating plate to make bearing removal easy.
Be careful with the hot gear case and relative parts. They maybe hot enough to burn you severely.
• Pull the drive pinion (G) off the gear case (F) together with the ballbearings (H, J) and then pull the cutting tool shaft (B) off the gearcase (F) together with the ball bearing (K) and the bevel gear (L).
• Hit the gear case against a wooden block to get the ball bearing (M)falling out of the gear case (F).
• Remove the circlip (N) out of the pinion (G) to separate the ballbearings (H, J) from the pinion (G).
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2-10 POWER TRAINGear Case
Reassembly — KBL23A/KB 26A• Reassembly is the reverse of disassembly.
• Adjusting clearance (X) as specified, install the cover (L) on the gearcase (D).
Specified Clearance0.2 to 1.0 mm (0.008 to 0.04 in.)
Gear Case LubricationUse a heavy duty grease for lubrication of the bevel bearing. The
grease level should be checked after first 50 hours of operation andadded as necessary. Thereafter check every 20 hours of operation. Todo this, release to remove the filler plug (F) on the side of the gear case(C). If no grease can be seen inside the gear case, squeeze grease intothe gear case. Do not squeeze grease more than 10g at a time.
CAUTION
The gear case must not be completely filled with grease, i,e,heat during normal operation would cause grease to be forcedout of the gear case.
KBL23A/KB 26A
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Be careful not to injure your hands with the steel cutter blade.
• Turn the brushcutter upside down on the ground with its cutting toolshaft (E) upward.
• Put the holder (A), the steel cutting blade (B), and the holder (C) overthe cutting tool shaft (E).
Take care that the steel cutting blade (B) is centered by putting itcorrectly on the socket and spigot joint.
Put the steel cutting blade (B) with its arrow side marked upward, onthe upper holder (C), and center the lower holder (G) on the cuttingblade (B).
Make sure the steel cutting blade (B) is correctly centered with thesocket and the spigot joint between upper and lower holders (C, G).
• Aligning the hole of the holder (C) with the hole (F) on the gear case,insert a wrench provided into the gear case through both holes tokeep the shaft from turning.
• Tighten down the nut (D) to the specified torque by turning itcounterclockwise.
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2-12 POWER TRAINCutting Head
Cutting Head InstallationThe nylon-cord cutter head (A) has a left-handed mounting thread.
• Turn the brushcutter upside down on the ground with its cutting toolshaft (B) upward.
• Aligning the hole of the holder (C) with the hole (F) on the gear box;insert a wrench provided, into the gear case to keep the cutting toolshaft (B) from turning.
Take care that the cover (G) is centered by putting it onto socket andspigot at between the holder (C) and the holder (D).
• Tighten the nylon-cord cutter head (A) by turning itself counterclock-wise with both hands as much as possible.
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POWER TRAIN 2-13Cutting Head except Australian Model
Disassembly• Do not push the spool (A) in. Hold the drum (B) firmly and turn the
spool (A) clockwise to take up slack, then twist with a hard snap untilplastic peg (C) is between the holdes (D&E).
• Pull the spool (A) out of the drum (B).
Reassembly• Use one line, 6 m (20 ft.) long.
• Thread end of the line (A) through the hole (B) on the spool (C) andpull through until the line (A) is the same length on both sides of thehole (B).
• Wind both ends of the line (A) counterclockwise at same time.
CAUTION
Wind tightly and evenly from side to side and do not twist theline (ignore the ridge).
• Feed ends of the line out through the eyelets (A) on the drum (B).
CAUTION
Keep line as tight as possible and do not let it slip under thespool into the drum.
• Align the peg (A) on the drum with the slots in the spool and pushthe spool into the drum.
• Hold the drum (B) firmly, twist the spool (C) sharply in direction shown,until the peg (A) goes into the hole (D) with a click and locks the spool(C) to the drum (B).
• Cut the lines to about 100 mm (4 in.) long.
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2-14 POWER TRAINCutting Head — Australian Model
Disassembly• Turn the set screw (A) in accordance with the arrow (B) marked at
the bottom of the head.
• Remove the set screw to disassemble the cutting head as shown.A. RetainerB. SliderC. Return SpringD. SpoolE. LineF. CaseG. Set Screw
Reassembly• Use one line, 6 m (20 ft.) long.
• Turn down the line in two in order that one side is about 150 mm(5.90 in.) longer than the other side.
• Hitch the line to the hook on the spool at its turned point. Wind bothends of the line on the spool at the same time
CAUTION
Wind tightly and evenly from side to side and do not twist theline (ignore the ridge).
• After the line was wound, have both sides of the line caught in thenotches in order to pull both ends of the line out of the notches about150 to 200 mm (5.90 to 7.87 in.) long.
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POWER TRAIN 2-15Cutting Head — Australian Model
• Feed ends of the line (A) through eyelets (B) on the case (C).
• Align the notches of the spool (A) with the eyelets (B) of the case toinsert the spool onto the case core (C).
• Pull both ends of the line (D) to complete the spool installation.
• Set the latch of the return spring into the notch (A) of the slider (B)as shown.
• Insert another latch of the return spring into the notch of the spoolmarked with � (A) to such a depth as to enable to turn the slider.
• Holding the slider (A) to align the latch of the return spring with �marked on the spool, push the slider (A) into the case.
• Twist it within about 30 degrees of angle to get both top and bottomlatches of the return spring settled in.
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2-16 POWER TRAINCutting Head — Australian Model
• After the slider (A) was pushed onto the case core, take the slider (A)in and out to check that it can move free.
• While pushing this slider onto the case, insert the retainer (A) into thecase.
• While holding the retainer, press the case which has been set ontothe cutting tool shaft attached to the equipment.
Operation Check• After the mowing head was assembled, check if the mowing head
operates correctly: Tap the ground 2 or 3 times with the mowing head, if the mowing
head clicks. Pull both ends of the line out of the mowing head, if both ends of the
line can be pulled out of the mowing head.
• Pull both ends of the line out of the mowing head to remove slackand then cut them 120 to 150 mm (4.72 to 5.90 in.) long.
Gear Case Service• Use high quality gear lubricant grease.
• Check grease level every 50 hours of operation. If no grease canbe seen on the inside of the filler plug, fill the gear case (A) withgrease, until grease comes out of the pinion gear shaft. About 8 to10 grams (full case) of grease for KBL23A/KB 26A and 13 to 17grams (full case) of grease for KB 33A/KB 34A/KB 43A/KB 48Aare necessary.B. Grease Tube
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POWER TRAIN 2-17Cutting Head — Australian Model
Drive Shaft ServiceThe drive shaft is supported in 5 bearing-pushes inside the guard
tube. It is impossible to replace the bearing-bushes, i. e. the completeguard tube has to be replaced in case of bearing damage.
• Inspect film of lubricant every 50 hours of operation. If film of lubricanton the drive shaft is broken in places, coat the areas concerned withgrease.
CAUTION
Do not apply too much grease to the drive shaft.Never pump grease into the guard tube.
Bearing-Bush before Assembly
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ENGINE 3-1
ENGINE
Table of Contents3
Clutch and Fuel Tank.........................................................................................................................................................3-2Removal.......................................................................................................................................................................3-2Installation....................................................................................................................................................................3-2
Air Cleaner, carburetor, and Muffler...................................................................................................................................3-3Removal.......................................................................................................................................................................3-3Installation....................................................................................................................................................................3-3
Recoil Starter, Shroud, Fan Housing, and Ignition Coil.....................................................................................................3-4Removal.......................................................................................................................................................................3-4Installation....................................................................................................................................................................3-4Ignition Coil Inspection................................................................................................................................................3-5
Flywheel and Cylinder........................................................................................................................................................3-6Removal.......................................................................................................................................................................3-6Installation....................................................................................................................................................................3-7
Piston and Piston Ring.......................................................................................................................................................3-8Removal.......................................................................................................................................................................3-8Installation....................................................................................................................................................................3-8
Crankcase and Crankshaft — KBL23A/KB 26A/KB 34A/KB 43A/KB 48A.................................................................3-9Removal.......................................................................................................................................................................3-9Installation....................................................................................................................................................................3-9
Crankcase and Crankshaft — KB 33A/KB 34A............................................................................................................3-10Removal.....................................................................................................................................................................3-10Installation..................................................................................................................................................................3-10
Crankcase and Crankshaft — KBL23A/KB 26A/KB 33A/KB 34A..............................................................................3-11Crankshaft Shim Selection........................................................................................................................................3-11
Crankcase and Crankshaft — KB 43A/KB 48A............................................................................................................3-12Crankshaft Shim Selection........................................................................................................................................3-12
Crankcase and Crankshaft...............................................................................................................................................3-13Crankshaft Shim Installation......................................................................................................................................3-13
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3-2 ENGINEClutch and Fuel Tank
Removal• Keeping the clutch shoes (A) from turning by using a pair of pliers,
release the clutch pins (B) by turning counterclockwise to remove theclutch shoes (A) and the clutch assembly.
Take care not to scratch the clutch shoes (A). Do not remove the clutch spring (C) if not needed.
• Remove the stand (D).
• Remove the tank grommet (E) out of the fuel tank (F).
• Loosen the fuel tube clamps to remove the fuel tank (F) together.
Installation• Installation is the reverse of removal.
NOTE Apply a bit of 2–stroke engine oil to the grommet in order to make
the insertion easy.
• Fix the fuel filter to the delivery side opaque tube and clamp it.
• Install the tank grommet to the fuel tank so that the transparent tubecomes toward the fuel tank center.
• Put the opaque tube into the fuel tank together with the fuel filter andfit the tank grommet into its hole in order that the raised letters on thetank grommet can look toward outside.
• Apply locking agent to screw threads of the clutch pins (B).
• Apply a bit of heat resisting grease to the clutch-pin holes.
• Put the clutch shoes (A) and the plate (G) on the flywheel with raisedletter(s) such as R54 for KB 26A, R78 for KB 43A/KB 48A, andR for KB 33A/KB 34A toward you to install them by tightening theclutch pins (B) to the specified torque.
• Install the clutch spring (C) to the clutch shoes (A) before installingthe clutch shoes (A) on the flywheel if the clutch spring is removed.
KBL23A/KB 26A
KB 43A/KB 48A
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ENGINE 3-3Air Cleaner, carburetor, and Muffler
Removal• Unscrew the shroud mounting screw to remove the shroud.
• Unscrew the air cleaner mounting screws (A) to remove the air cleanerassembly (B).
• Unscrew the two carburetor mounting-screws (C) to remove thecarburetor together with the gaskets (D, F) and the insulator (E).
NOTE Do not remove the carburetor if not needed.
• Unscrew the muffler cover mounting-screws (G) to remove the mufflercover (H).
• Unscrew the four muffler mounting-screws (J) to remove the mufflerbody (K) and the baffle plate (L).
• Unscrew the two flange bolts (M) to remove the muffler body-complete(N) together with the gasket (P) and the flange (Q).
NOTE In ordinary circumstances, there is no need to remove the muffler
body complete (N) out of the cylinder.
KBL23A/KB 26A
KB 43A/KB 48A
Installation• Installation is the reverse of removal.
• Use new gaskets.
• If the insulator (A) is removed, fit the screw to round seat and nuts(D) to the hexagonal seats in the insulator (A), and put the insulatorgasket (B) onto screw ends as shown, then install the insulator onthe cylinder (C) with the screws.
Each pulse hole must align.
KB 43A/KB 48A
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3-4 ENGINERecoil Starter, Shroud, Fan Housing, and Ignition Coil
Removal• Remove the four mounting screws (A) to remove the recoil starter (B).
• Release the starting pulley locknut (C) counterclockwise to remove ittogether with the washer (D).
• Remove the starting pulley (E) by turning itself counterclockwise.
• Remove the spark plug cup (F) out of the spark plug (G).
• Remove the plug cup (F) out of the high tension cord (M).
• Remove the shroud (H).
• Disconnect the ignition lead wire (J).
• Remove the fan housing (K).
• Remove the ignition coil (L).
KBL23A/KB 26A
KB 43A/KB 48A
Installation• Installation is the reverse of removal.
• Adjust the ignition coil air gap to the specified value.
Ignition Coil Air Gap Specified[KBL23A/KB 26A/KB 34A/KB 43A/KB 48A]
0.3 to 0.5 mm (0.011 to 0.019 in.)[KB 33A]
0.4 to 0.5 mm (0.015 to 0.019 in.)
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ENGINE 3-5Recoil Starter, Shroud, Fan Housing, and Ignition Coil
• Install the starting pulley to the crankshaft by turning clockwise. The recoil pawl must be fitted on the pulley as shown.
Ignition Coil InspectionThe ignition coil has been integrated with an igniter being solid-state.
• Use the Kawasaki hand tester (P/N 57001–1394); resistance valuemay vary with individual meters.
• Set the Kawasaki hand tester to the specified range.
• Connect the test leads to the points shown and read the resistance.If the resistance is not as specified, replace the ignition coil.If the meter reads as specified, the ignition coil windings probablygood. However if the ignition system still does not perform as itshould after all other components have been checked, replace theignition coil with one know to be good.
Ignition Coil Specified Resistance
Resistance Between
[B] and [C] [A] and [C]
Primary Winding Secondary Winding
KBL23A/KB 26A 0.8 to 1.2 (Rx1 ) 9 k to 15 k (Rx1 k)
KB 33A 0.3 to 0.7 (Rx1 ) 9.3 k to 15.6 k (Rx1 k)
KB 34A 0.4 to 0.6 (Rx1 ) 8 k to 13 k (Rx1 k)
KBH43A/KBH48A 0.7 to 1.2 (Rx1 ) 9.4 k to 15.6 k (Rx1 k)
NOTE It is unable to inspect the igniter whether it is good or bad with the
Kawasaki hand tester since it was integrated with the ignition coil. Whenever you have doubt as to function of the igniter to operate,
try replacing the ignition coil with one known to be good.
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3-6 ENGINEFlywheel and Cylinder
Removal• Release the flywheel nut (A) counterclockwise to remove it together
with the spring washer (B) and the plain washer (C).
• Release the flywheel (H) out of the crankshaft by using a puller (I) asshown.
• Remove the key (D) from the crankshaft.
• Unscrew the flange bolts (E) to remove the cylinder (F) and thecylinder gasket (G) from the crankcase.
• Scrape the carbon deposits inside the cylinder with a suitable tool. Use a scraper that are mode of a material that will not cause damage.
KBL23A/KB 26A
KB 43A/KB 48A
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ENGINE 3-7Flywheel and Cylinder
• Check to see if the pulse hole (A) under the inlet port (B) is clogged.If clogged, clean.
KBL23A/KB 26A
InstallationThe cylinder gasket has the notches allowing crankcase pulses to
pass through. The cylinder gasket should be properly set according thefollowing.
• Installation is the reverse of removal.
• Use a new gasket.
• Set the cylinder gasket with its direction as shown.
• Evenly tighten the cylinder to the crankcase with tightening torqueand order specified (see Tightening Torque).
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3-8 ENGINEPiston and Piston Ring
Removal
CAUTION
Do not reuse snap rings as removal weakens and deformsthem. They could fall out and score the cylinder wall.
• Remove snap rings (F) out of the piston (B).
• Pull the piston pin (C) off the piston (B) to remove the piston (B) andthe needle bearing (D) out of small-end of the connecting rod (E).
• Remove piston rings (A) out of the piston (B).
Installation• Installation is the reverse of removal.
• Position the piston rings (A) in order that the radii at the ring gap canmeet at the piston ring stopper pin (B) in the piston groove when therings are compressed.
• Fit the needle bearing into small end of the connecting rod to installthe piston to small end of the connecting rod, with the mark (A) onpiston crown pointing to specified side, with the piston pin.
KB 33A
• “Arrow” on piston crown should point to flywheel side.KBH43A
• “E” on piston crown should face muffler side.KBL23A/KB 26A/KB 34A/KBH48A
• “H” on piston crown should face muffler side.
KB 33A
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ENGINE 3-9Crankcase and Crankshaft — KBL23A/KB 26A/KB 34A/KB 43A/KB 48A
Removal• Unscrew the tightening screws to split the crankcase (2) from the
crankcase (1). Lightly tap the crankcase with a plastic hammer to split it. Take care not to damage the oil seals. Take care not to lose the adjusting shims. (0 to 3 pieces).
InstallationThe crankshaft, the connecting rod, and the needle bearing are
inseparable. This means that the crankshaft must always be replaced asa complete unit in the event of damage to any one of these parts whenfitting a replacement always install new ball bearings. The completecrankcase must be replaced if either half is damaged.
• Installation is the reverse of removal. Apply fine oil to both ball bearings. Apply heat resisting grease between oil seal lips.
• If the original crankcase if reused, remove liquid must be cleanedthoroughly to ensure a perfect seal.
• Sparingly apply liquid gasket on the sealing surface of the starter halfof the crankcase.
CAUTION
Excessive amounts may block something inside and causeserious damage.
• Put the flywheel half of the crankcase onto the starter half of thecrankcase so that the dowel pins can be fit into their holes of theflywheel half of the crankcase and tighten the bolts to the specifiedtorque evenly in the order shown (see Tightening Torque).
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3-10 ENGINECrankcase and Crankshaft — KB 33A/KB 34A
Removal• Unscrew the tightening screws to split the crankcase (2) from the
crankcase (1). Lightly tap the crankcase with a plastic hammer to split it. Take care not to damage the oil seals. Take care not to lose the adjusting shims (0 to 3 pieces).
InstallationThe crankshaft, the connecting rod, and the needle bearing are
inseparable. This means that the crankshaft must always be replaced asa complete unit in the vent of damage to any one of these parts whenfitting a replacement always install new ball bearings. The completecrankcase must be replaced if either half is damaged.
• Installation is the reverse of removal. Apply fine oil to both ball bearings. Apply heat resisting grease between oil seal lips.
• If the original crankcase is reused, remove the gasket stuck and cleanthe sealing surfaces;They must be cleaned thoroughly to ensure a perfect seal.
• Put the new gasket on the sealing surface of the crankcase so thatthe dwel pins are in position or fit them in the new gasket and tightenthe bolts to the specified torque evenly in the order shown. (SeeTightening Torque).
• Carefully cutaway any crankcase gasket that is proud of the cylinderflange surface.
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ENGINE 3-11Crankcase and Crankshaft — KBL23A/KB 26A/KB 33A/KB 34A
Whenever any one of the crankshaft, the crankcase, and the ballbearing is replace; select the crankshaft shim(s) to adjust crankshaftaxial play according to crankshaft shim selection.
Crankshaft Shim SelectionMeasure dimension of A, B, and C shown in the figure and calculate
crankshaft clearance (dimension D) by the following equation.Important: Measure dimension of A and B at the outer race not to allowball bearing axial play to affect the shim selection.
Shim thickness mm (in). Shim Part No.0.2 (0.007) (1) 92025-2104
0.4 (0.015) (2) 92025-2105
0.6 (0.023) (3) 92025-2106
Clearance (dimension D) mm Shim
0.05 0.27 without shim
0.28 0.47 (1)
0.48 0.67 (2)
0.68 0.79 (3)
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3-12 ENGINECrankcase and Crankshaft — KB 43A/KB 48A
Whenever any one of the crankshaft, the crankcase, and the ballbearing is replaced; select the crankshaft shim(s) to adjust crankshaftaxial play according to crankshaft shim selection.
Crankshaft Shim SelectionMeasure dimension of A, B, and C shown in the figure and calculate
crankshaft clearance (dimension D) by the following equation.Important: Measure dimension of A and B at the outer race not to allowball bearing axial play to affect the shim selection.
D = A + B - C
KB 43A/KB 48A
Shim thickness mm (in). Shim Part No.
0.2 (0.007) (1) 92025-2135
0.4 (0.015) (2) 92025-2136
0.6 (0.023) (3) 92025-2137
Clearance (dimension D) mm Shim
0.05 0.27 without shim
0.28 0.47 (1)
0.48 0.67 (2)
0.68 0.79 (3)
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ENGINE 3-13Crankcase and Crankshaft
Crankshaft Shim Installation• Install shim(s) selected onto the crankshaft as shown and assemble
the crankcase.
Crankshaft Axial PlayStandard: 0.05 0.295 mm (0.002 0.011 in.)*
* does not include that of ball bearings.
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TROUBLESHOOTING 4-1
TROUBLESHOOTING
Table of Contents4
Engine Troubleshooting......................................................................................................................................................4-2Hard Starting...............................................................................................................................................................4-2Engine Malfunction at Low Speed ..............................................................................................................................4-3Engine Malfunction at High Speed..............................................................................................................................4-3Insufficient Power ........................................................................................................................................................ 4-4Abnormal Engine Noises.............................................................................................................................................4-4Hunting ........................................................................................................................................................................4-4Fuel Leakage from Carburetor....................................................................................................................................4-4Excessive Fuel Consumption......................................................................................................................................4-4Engine Stops during Operation...................................................................................................................................4-5
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4-2 TROUBLESHOOTINGEngine Troubleshooting
Hard Starting
Symptom Cause RemedyPulling recoil starter handle Poor compression •Wear in piston •Replacewould not cause sufficient •Wear in piston ring •Replacecompression •Stick of piston ring •Clean ring groove and
replace piston ring•Wear or deformation of •Replace cylinder and
clinder boce. piston ring as a set•Poor tightening of cylinder •Tighten
and spark plugAfter choking and making Insufficient fuel •No fuel in fuel tank •Replenishseveral starting attempts, it is •Clogging of dust or entry of •Cleanfound, on removing spark air in fuel pipeplug, that electrodes are still •Clogged fuel tank cap air vent •Cleandry. •Foul fuel filter in fuel tank •Clean
•Poor opening and closing of •Correctchoke valve
•Air entering at gasket fitted to •Tighten or replace gasketcarburetor flange
•Clogged carburetor needle jet •Cleanor main jet
After choking and making Excess fuel •Faulty choking (In summer, or •Remove spark plug, withseveral starting attempts, it is when engine is warm, full engine switch OFF,on removing spark choking gives too rich mix-
ture)exhaust excess fuel by
plug, that electrodes are pulling starter ropeexcessively wet. •Overflow of fuel from •Check carburetor and
carburetor exhaust excess fuel fromcylinder
•Clogged air cleaner •Clean aircleaner andexhaust excess fuel fromcylinder
On removing spark plug, Faulty fuel •Mixture of water into fuel •Change fuelmoisture condensed on spark •Deterioration in fuel because •Change fuelplug electrodes. of poor long-term storage
•Use of fuel other than •Change fueldesignated
Make spark check. Faulty spark plug •Electrodes are burned and •Correct gap or replaceNo spark but spark appears on damaged to cause too widespark plug replaced. gap
•Much carbon bridging •Clean or replaceelectrodes gap
•Small foreign matter being •Cleancaught between electrodes
•Faulty insulation of electroes •Clean or replace sparkplug
No spark in any spark plug, Faulty plug cap •Faulty contacting at •Remove plug cap andbut spark appears when the spark plug cap connect terminal againend of high tension cord istouched to engine block.
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TROUBLESHOOTING 4-3Engine Troubleshooting
Symptom Cause RemedyNo spark or very week spark at the end of high tension cord
Spark appears when stop Faulty stop switch •Stop switch lead wire is •Correctswitch wire is jammeddisconnected at •Short circuit in stop switch •Replaceconnector.No spark appeas even Slow recoil starter •Recoil starter revolution is •Pull recoil starter ropewhen stop switch wire is revolution lower than that igniter more rapidlydisconnected at begins to work.connector.Spark appears when Faulty ignition •Wiring of coil coming short- •Replaceignition coil is replaced coil circuited or disconnectedwith new one. •Stop lead wire is jammed •Correct or replaceSpark appears when Faulty flywheel •Flywheel damagnetized •Replaceflywheel is replacedwith new one.
Engine Malfunction at Low Speed
Symptom Cause RemedyWhen throttle value is opened •Faulty carburetor •Clogging in carburetor inside •Disassemble and cleangaradually, revolution speed •Faulty fuel filter •Foul fuel filter •Clean or replacedrops at some position or •Air enters at •Faulty carburetor gasket •Replaceengine stops carburetor flange •Incomplete fitting of carburetor •TightenWhen spark test of spark plug •Faulty ignition •Faulty insulation of spark plug •Replaceis made with recoil starter rope system •Foul electrodes •Cleanpulled, spark appears veryweek.
•Faulty magneto (flywheel, igni-tion coil and related parts)
•Replace
Engine Malfunction at High Speed
Symptom Cause RemedySame as "Engine Malfunction •Faulty carburetor •Same as "Engine Malfunction •Same as "Engineat Low Speed" mentioned •Faulty fuel filter at Low Speed" Malfunction at Lowabove •Faulty ignition
systemLoaded operation causes •Clogged fuel tank cap air vent •Cleanrevolution fluctuation with big •Dust clogging in or entry of air into fuel pipe or •Cleanfrequency carburetor
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4-4 TROUBLESHOOTINGEngine Troubleshooting
Insufficient PowerSymptom Cause Remedy
Same as "Hard Starting" •Poor compression •Same as "Hard Starting" •Same as "Hard Starting"•Insufficient fuel•Excess fuel•Faulty fuel•Faulty magneto•Faulty igniter
Engine overheated •Clogged air cleaner •Clean•Carbon deposit inside combustion chamber •Clean•Inappropriate mixing ratio (too little oil) •Change fuel•Broken cooling fan blade •Replace•Dirt or dust attached to cooling fins of cylinder •Clean
frequency •Grass of dirt attached to cooling air passage and •Cleanflywheel blade
Thick smoke issues from Excess fuel •Same as "Hard Starting" •Same as "Hard Starting"exhaust port. Faulty exhaust •Carbon deposit narrows •Clean
system exhaust passage and muffler•Excessive oil mixed •Change fuel
Engine knocking •Interior fuel •Change fuel
Abnormal Engine Noises
Symptom Cause RemedyPiston Slapping •Cylinder and piston ring wear •Replace
•Wear and/or deformation in piston •Replace•Carbon deposit inside combustion chamger •Clean•Wear in piston pin and connecting rod small end •Replace
bearing•Wear in piston and piston pin •Replace
Connecting rod noise •Wear in large and small end bearings •Replace
Hunting
Symptom Cause RemedyHunting •Foul air cleaner •Clean
•Dust clogging in or air entry into fuel pipe •Clean•Clogged fuel tank cap air vent •Clean•Clogged carburetor •Clean
Fuel Leakage from Carburetor
Symptom Cause RemedyFuel leak from carburetor •Foreign matter attached to needle valve and/or •Clean
valve seat •Clean•Correction or wear in needle valve and/or valve seat •Replace needle valve
assembly•Poor tightening of diaphragm gasket •Tighten or replace
Excessive Fuel Consumption
Symptom Cause RemedySame as "Hard Starting" •Poor compression •Same as "Hard Starting" •Same as "Hard Starting"Sufficient compression but •Too rich fuel mixture •Adjustexcessive fuel consumption. •Inferior fuel •Replace
•Foul air cleaner •Clean•Too high idling speed •Adjust•Choke valve not fully open •Adjust
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TROUBLESHOOTING 4-5Engine Troubleshooting
Engine Stops during Operation
Symptom Cause RemedyDifficulty in cranking, or Overheat •Excessively lean fuel •Adjust carburetorseizure mixture (too little fuel)
•Inferior lubricating oil mixed •Change fuel•Excessive carbon deposit in •Clean
conbustion chamber•Dust accumulation on cooling •Clean
fins of cylinderCranking is easy Faulty electrical •Faulty spark plug •Clean or replace
system •Faulty magneto •Check and repair•Loseness in connections •Check and repair
Faulty fuel system •Clogged fuel line •Clean•Foul air cleaner •Clean or replace•Fuel in tank used up •Replenish
Faulty carburetor •Dust clogging in fuel passage •Clean
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SUPPLEMENT 5-1
SUPPLEMENT
Table of Contents
5Rotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A.......................................................................5-2
Rotary Valve, Diaphragm Type Carburetor Troubleshooting — KBL23A/KB 26A/KB 34A ............................................5-7Piston Valve, Diaphragm Type Carburetor — KB 33A/KB 43A/KB 48A.....................................................................5-10
Disassembly .............................................................................................................................................................. 5-10Reassembly...............................................................................................................................................................5-11Metering Chamber Adjustment..................................................................................................................................5-11Main Adjust Screw Adjustment..................................................................................................................................5-12Lowest Throttle Valve Adjustment.............................................................................................................................5-12Priming Pump System...............................................................................................................................................5-13Choke System...........................................................................................................................................................5-14Idling System.............................................................................................................................................................5-14Fuel and Air Flow between Idling and Full Throttle..................................................................................................5-15Fuel and Air Flow at Full Throttle..............................................................................................................................5-15
Piston Valve, Diaphragm Type Carburetor Troubleshooting — KB 33A/KB 43A/KB 48A..........................................5-16Spark Arrester — KBL23A/KB 26A/KB 34A for US only..............................................................................................5-18
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5-2 SUPPLEMENTRotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A
Priming Pump SystemWhen starting the engine, by pushing the priming pump (18), air is
pushed out toward the overflow pipe (21) from the priming pump checkvalve (20), which causes negative pressure inside the metering chamber(13) and the needle valve (7) opens.
Then fuel from the fuel tanks is sucked into the metering chamberthrough the inlet cheek valve (4) and then into the priming pump. Andexcessive fuel is discharged from the overflow pipe. This operation iscalled “Priming operation at starting”.Non emission type
emission type
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SUPPLEMENT 5-3Rotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A
Fuel Pump SystemAfter starting the engine, part of pressure change inside the
crankcase caused by engine revolution is transmitted to the pumpdiaphragm (2) through the engine pulse passage(1), which deformsthe pump diaphragm and it starts reciprocating motion. Namely, fuelis sucked from the tank into the carburetor under pressure by volumechange due to the pump diaphragm’s reciprocating motion and theinlet (4) and the outlet check valves (5) function.
Metering Chamber SystemThe main diaphragm (10) forming the metering chamber senses
inside fuel pressure change of the metering chamber (13), which occursin accordance with the engine revolution change, as vertical motion.And it works to keep a uniform pressure (equivalent to the fuel surfaceof a float type carburetor) inside the metering chamber by opening andclosing the needle valve (7).
Fuel in the metering chamber is drawn by negative pressure in theventuri, blown out from the main nozzle (17), mixed with air passedthrough the venturi and sucked into the engine. When the engine stops,negative pressure in the venturi becomes zero; the control lever (11) ispushed up with the valve spring (12); and the needle valve (7) closes.Then fuel flow stops and overflow is prevented.
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5-4 SUPPLEMENTRotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A
DisassemblyBefore disassembling, clean the carburetor with cleaning oil so that
no dirt enters the carburetor.
• Remove 2 throttle-collar screws (1) to remove the throttle valveassembly (3) from the carburetor body (4).
CAUTION
Do not disassemble the throttle valve assembly (3).
• Remove 4 pump-cover screws (21) with the priming pump (19) sideupward.
• Remove the priming pump cover (20), the priming pump (19), the airpurge body (18), the main diaphragm (18), the gasket (16), the pumpbody (15), the pump diaphragm (8), and the pump gasket (7) in thatorder.
• Remove the main jet (6) and the O-ring (5) from the carburetor body(4).
CAUTION
Do not remove the main nozzle (22) as it is press fitted.If much dirt is found inside the carburetor, especially on theinlet screen, clean the fuel tank inside and replace the fuelfilter.
ReassemblyBefore reassembly, clean removed parts and the body with suitable
detergent and use compressed air to dry.
• Reassembly is the reverse of removal.
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SUPPLEMENT 5-5Rotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A
Inspection and Adjustment• Clean the carburetor with cleaning oil and apply air.
• Check to see that no dirt or corrosion is found in the main jet.If dirt is found, clean and apply air.If corrosion is found, replace the main jet with new one.
CAUTION
When replacing the main jet, be sure to replace with a jet withthe same number.
• As to the gaskets, check to see if no deformation or damage is found.If deformation or damage is found, replace them with new ones.
• Check the pump diaphragm to see if no damage or hardening is found.Check the inlet check valve and the outlet check valve in particularand make sure that they are flat and not bent.If they are bent, replace them with no ones.
• Check the main diaphragm to see if there is any peeling, damage orthe aluminum plate bent.If they are bent, replace with new one.After cleaning the pump body, check to see that the control leverfunctions well and that no dirt is found on the inlet screen.
CAUTION
To prevent deformation or sticking of the main check valve,never apply high pressure air to the valve.
• Check to see that there is no deformation or damage on the checkvalve.If any, replace it with new one.
• Check to see that no hole, damage or abnormal hardening is presenton the priming pump.If present, replace it with new one.
• Push the tip end of the control lever lightly and make sure that thelever moves smoothly.If the needle valve which opens and closes with movement of thecontrol lever (1), has got some damage on its tip end or wear due toits long use, applying air to the tip end of the needle valve (3) will notbe solution for overflow.In this case, replace the pump body assembly with new one.
• Adjust the control lever (1) so as to be at the same level as the bottomof the metering chamber as shown.If correction is necessary, ben the lever lightly to be on the samesurface of the metering chamber bottom, or adjust the lever to befrom 1.4 mm (0.055 in.) to 1.6 mm (0.062 in.) with surface of thepump body as standard.
• To check function of the main check valve, stick vinyl pipe end to themain check valve and breathe in and out from the other end.If the valve opens when breathing in and closes when breathing out,the valve functions well.
• If any problems are found, soak the valve in gasoline for about 10minutes and repeat breathing in and out several times.If no improvement shows, replace the pump body (2) with new one.
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5-6 SUPPLEMENTRotary Valve, Diaphragm Type Carburetor — KBL23A/KB 26A/KB 34A
Idle Needle Pin Adjustment• Start the engine and move the throttle lever to its fully-closed position.
Raise the engine speed just before the cutting tool begins turning byturning the idle adjust screw clockwise.
• Adjust the idle needle pin where the engine speed rises highestby turning it clockwise or counter clockwise. When the enginespeed rises and the cutting tool begins turning, lower the enginespeed by turning the idle adjust screw counterclockwise and readjustthe idle needle pin where the engine speed rises highest rightbefore the cutting tool begins turning by turning the pin clockwiseor counterclockwise.
• When the idle needle pin position is fixed, turn the idle needle pin 1/4 to 1/2 turn more and stop turning.
• And then adjust the idle adjust screw to the specified speed. See“Setting Table”.
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Symptom Cause RemedyEngine hard to start •Idle needle pin maladustement •Adjust
•Idle adjust screw maladjustment •Adjust•Foul fuel filter in fuel tank •Clean•Clogging in fuel passage •Clean•Air leakage in fuel passage •Repair•Improper fuel •Change•Inferior check valve •Replace•Clogged air cleaner element •Clean or replace•Damaged carburetor control (metering) lever •Repair•Malfunction of carburetor control (metering) lever •Repair•Inferior main diaphragm gasket •Replace•Poor tightening of main diaphragm cover screw •Tighten•Damaged main diaphragm •Replace•Adherence of inlet needle valve •Replace•Inlet needle valve wear •Replace•Inlet needle valve sticking •Repair
Overflow, fuel leakage •Poor tightening of fuel pump cover screw •Tighten•Damaged carburetor control (metering) lever •Repair•Too high carburetor control (metering) lever •Adjust•Malfunction of carburetor control (metering) lever •Repair•Deformed carburetor control (metering) level spring •Replace•Inferior main diaphragm gasket •Replace•Poor tightening of main diaphragm cover screw •Tighten•Damaged main diaphragm •Replace•Inlet needle valve wear •Replace•Inlet needle valve sticking •Repair
Priming is hard to suck fuel •Clogged fuel tank cap air vent •Clean•Foul fuel filter in fuel tank •Clean•Clogged fuel line •Clean•Air leakage in fuel line •Repair•Damaged priming pump •Replace•Inferior priming pump check valve •Replace•Malfunction of carburetor control (metering) lever •Repair•Inferior main diaphragm gasket •ReplacePoor Tightening of main diaphragm cover screw •Tighten•Damaged main diaphragm •Replace•Adherence of inlet needle valve •Replace
Engine would not idle •Idle needle pin maladjustment •Adjust•Idle adjust screw maladjustment •AdjustFoul fuel filter in fuel tank •CleanAir leakage in fuel line •Repair•Interior manifold O-ring •Replace•Poor tightening of carburetor •Tighten
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Symptom Cause RemedyIdling is too slow •Idle needle pin maladjustment •Adjust
•Clogged air cleaner element •Clean or replace•Damaged carburetor control (metering) lever •Replace•Carburetor control (metering) lever is too high •Adjust•Malfunction of carburetor control (metering) lever •Replace•Inlet needle valve wear •Replace•Forein matter sicking •Clean
Idling is unstable •Idle needle pin maladjustment •Adjust•Idle adjust screw maladjustment •Adjust•Clogged fuel tank cap air vent •Clean•Foul fuel tank fuel filter •Clean•Clogged fuel line •Clean•Air leakage in fuel line •Repair•Improper fuel •Change•Inferior check valve (foreign matter) •Replace•Inferior manifold O-ring •Replace•Poor tightening of carburetor •Tighten•Malfunction of carburetor control (metering) lever •Replace•Poor installation of carburetor control lever •Correct•Damaged main diaphragm •Replace•Adherence of inlet needle valve •Replace•Foreign matter sticking •Clean
Idling does not continue •Idling needle pin maladjustment •Adjust•Idling adjust screw maladjustment •Adjust•Foul fuel tank filter •Clean•Clogged fuel line •Clean•Air leakage in fuel line •Repair•Inferior check valve (foreign matter) •Replace•Too high carburetor control (metering) lever •Adjust•Malfuncion of carburetor control (metering) lever •Replace•Deformation of carburetor control (metering) lever •Replace•Poor installation of carburetor control lever spring •Correct•Inlet needle valve wear •Replace•Foreign matter sicking of inlet needle •Clean
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
Symptom Cause RemedyEngine does not accelerate •Idle needle pin maladjustment •Adjust
•Clogged fuel tank cap air vent •Clean•Foul fuel tank filter •Clean•Clogged fuel line •Clean•Air leakage in fuel line •Repair•Pulse leakage from fuel pump •Repair•Clogged pulse passage •Clean•Poor tigtening of pump cover screw •Tighten•Inferior of pump diaphragm •Replace•Inferior of check valve •Repair•Inferior of manifold O-ring •Replace•Poor tigtening of carburetor •Tighten•Damaged carburetor control (metering) lever •Replace•Too low carburetor control (meterian) lever •Adjust•Malfunction of carburetor control (metering) lever •Replace•Poor installation of carburetor control (metering) lever •Correct•Damaged carburetor control (metering) lever button •Replace•Poor tightening of diaphragm cover •Tighten•Damaged diaphragm •Replace•Adherence of inlet needle valve •Replace
Engine stops when decelrating •Idle needle pin maladjustment •Adjust•Interior pump diaphragm •Replace•Too high carburetor control (metering) lever •Adjust•Malfunction of carburetor control (metering) lever •Replace•Inlet needle valve wear •Replace•Foreign matter stticking of inlet needle •Clean
Engine does not accelerate •Idle needle pin maladjustment •Adjustquick •Clogged air cleaner element •CleanMalfunction at high speed •Clogged fuel tank cap air vent •Clean
•Four fuel tank filter •Clean•Clogged fuel line •Clean•Air leakage in fuel line •Repair•Improper fuel •Change•Pulse leakage from pulse pump •Repair•Poor tightening of pump cover screw •Tighten•Inferior of pump diaphragm •Replace•Inferior of check valve •Replace•Clogged air cleaner element •Clean•Inferior of manifold O-ring •Replace•Poor tightening of carburetor screw •Tighten•Damaged carburetor control (metering) lever •Replace•Malfunction of carburetor control (metering) lever •Replace•Deformation of carburetor control (metering) lever •Replace•Poor installation of control lever spring •Correct•Damaged main diaphragm button •Replace•Inferior of main diaphragm gasket •Replace•Poor tightening of main diaphragm cover •Tighten•Damaged main diaphragm •Replace•Inlet needle valve wear •Replace•Foreign matter sticking of inlet needle •Clean
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DisassemblyBefore disassembling, clean the carburetor with cleaning oil so that
no dirt enters the carburetor.
• Unscrew to remove the plate (38) and the priming pump (37).
• Remove the pump cover (35), the gasket (34), the pump plate (33),the pump diaphragm (30), and the gaskets (29, 31, 32).
Check to see if the gaskets (29, 31, 32, 34) and the pump diaphragm(30) are not damaged, and confirm outflow of air from the other sideof the passage.
• Unscrew to remove the control lever (17), the control lever pin (18),the control lever spring (16), and the needle valve (15).
• Unscrew to remove the plate (22), the check valve (21), and thegasket (20).
• Remove the cap (1) and pull up the throttle wire to take out the throttlevalve (9).
• Remove the throttle wire from the throttle valve (9) to remove thespring (5), the retainer (6), and the jet needle (8).
CAUTION
Do not remove the needle clip (7) if adjusting is not necessary.
• Remove the throttle stop screw (10) and the main adjust screw (12)together with the springs (11, 14) from the carburetor body and checkto see if tip of each screw is not damaged and free from foreignmaterial.If abnormal condition is found on the throttle stop screw (10) or mainadjust screw (12), replace with new ones.
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
Do not remove the check valve installed into the priming pumpcover normary. If it is removed because of clogging with dustand so on, take care not to damage seat surface to the checkvalve and contact area of the valve. When removing the checkvalve, do not sue tip of a screw driver, a metal, and the like.
• Unscrew to remove the diaphragm cover, the main diaphragm, andthe gasket.
Check to see if the main diaphragm is not ripped or does not comeoff and the aluminum disk of the diaphragm is not deformed.If the diaphragm or the gasket is damaged, replace with new one.
ReassemblyBefore assembly, clean removed parts and the body with suitable
detergent and use compressed air to dry.
• Reassembly is the reverse of disassembly.
Metering Chamber Adjustment• Push tip of the control lever lightly to check smooth movement of the
control lever.
• After installation, check control lever height proper height is as shown;but if the lever and the plate are on much the same surface leverheight shows no problem in use. Use ruler as a simple method tocheck control lever height as shown. If necessary, adjust by bendingthe control lever slightly.
CAUTION
Excessively bending the lever to the body (down side asshown) results in faulty acceleration and the engine stopsduring operation. Bending the lever to the opposite side (upside as shown) results in excessive fuel consumption andimpossibility in starting due to overflow.
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Main Adjust Screw Adjustment• Turn the main adjust screw slowly clockwise until it stops at full closure
and then turn it out 1–1/8 turns for KB 33A or 1–1/2 +- 1/2 turns forKBH43A and KBH48A.
CAUTION
Turn the screw slowly because overturning (tightening) causesdeformation of tip of the screw and screw seat on the body andresults in malfunction of the carburetor.
Lowest Throttle Valve Adjustment• Adjust the lowest position of the throttle valve by turning the screw so
that opening of the throttle valve may reach about 1 mm (0.04 in.).
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Priming Pump SystemWhen starting the engine, by pushing the priming pump (12), several
times by hand pressure in metering chamber lowers and the maindiaphragm (9), the needle valve (8) is opened and fuel flows intometering chamber (21). Overflow from the chamber flows back intothe fuel tank through the fuel outlet (14). Pushing should be stopped assoon as overflow appears out of the fuel outlet (14). During operation ofthe priming pump (12), the main check valve (15) is closed by negativepressure to check air suction from the needle jet (18) into the meteringchamber (21).
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Choke SystemUse the choke lever to fully close the choke valve, open the throttle
lever half, turn the engine switch to “ON”, and pull the recoil starterrapidly until the engine fires.
At this time, intake negative pressure increases by choking, morefuel flows from the needle jet and rich (nanely, containing extra fuel)air-fuel mixture suitable for starting the engine is sucked into the enginecylinder. After the engine starts, open the choke valve gradually to fullopen position. In tense heat or when the engine is warm, open thechoke valve half or fully.
Idling SystemAt this time, throttle valve position is at the lowest in the carburetor
and opening of the valve becomes minimum.The minimum opening of the throttle valve is decided by adjusting the
throttle stop screw, and fuel flow rate is controlled by clearance betweenthe needle jet and the jet needle.
The slot on bottom surface of the throttle valve regulates the negativepressure on the needle jet to give fuel flow appropriate for idling.
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Fuel and Air Flow between Idling and Full ThrottleWhen increasing the throttle valve opening, clearance between the
needle jet and the jet needle increases gradually and fuel flow rate fromthe jet and the jet needle increases gradually and fuel flow rate fromthe jet also increases. Fuel flow rate is controlled by the clearance. Bythis movement of the throttle valve, at the same time, intake air amountpassing through the carburetor also increases, and air-fuel mixture tomeet requirement of the engine from idling to high speed running canbe supplied.
Fuel and Air Flow at Full ThrottleAt this time, the throttle valve is positioned at the highest in the
carburetor and opening of the valve becomes maximum (full). Fuelflow rate is controlled largely by the main jet and opening of the jet isadjusted by the main adjust screw.
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
Condition Probable cause RemedyHard •No fuel drain into •Clogging in fuel tube at inlet •Remove and clean the tube.starting the return pipe in side.
spite of several •Broken tube at inlet side •Replace the tube.priming operation. •Air leakage from joint portion of •Fit fuel tube to the joint. If not
fuel tube at inlet side. good, replace the tube.•Adhesion of dust to check valve •Disassemble and clean parts.
of priming pump.•Broken check valve of priming •Replace the check valve or
pump or damaged seat surface the pump cover.of pump cover.
•Air leakage from fitting area of •Retighten screws to primingpriming pump. pump plate.
•Broken priming pump. •Replace the pump.•Air leakage from main check •Disassemble and clean the
valve. check valve. If not good,replace the main check valveand the plate.
•Loose main diaphragm cover. •Retighten screws to thediaphragm cover.
•Broken main diaphragm. •Replace the main diaphragm.•Broken main diaphragm gasket. •Replace the gasket.
•Fuel drains into the •Choke valve not closed. •Close choke valve.return pipe by •Air entering engine through the •Retighten the fitting bolts ofpriming operation, fitting portion of carburetor. the carburetor.but engine does •Main adjust screw not adjusted •Adjust the screw properly.not start. properly.
•Clogged needle jet. •Disassemble and clean.•Overflow of fuel from needle jet •Disassemble and clean
to the venturi of carburetor. needle valve portion, andadjust the control lever heightproperly. If not good, replacethe needle valve.
•After starting, engine •Choke valve closed after •Open choke valve afterrevolution does starting. starting.not continue. •Clogged pulse passage. •Disassemble and clean the
pulse passage.•Improper height of control lever. •Adjust the control lever
height properly.
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
Condition Probable cause RemedyEngine •Unstable idling and •Air entering engine through the •Retighten the fitting bolts ofmalfunction the running does not fitting portion of carburetor. the carburetor.at low not continue. •Too low idling speed (rpm). •Adjust the idling speed withspeed throttle stop screw.
•Clogged main check valve. •Disassemble and clean thecheck valve portion.
•Clogged needle jet. •Disassemble and clean.•Improper position of clip to jet •Insert the clip to the proper
needle. position (2nd stage) of jet needle.•Worn jet needle or needle jet. •Change the clip to upper
position of jet needle. If notgood, replace the jet needleand the carburetor body.
•Improper height of control lever. •Adjust the control leverheight properly
•Engine does not •Clogging in fuel tube at inlet •Remove and clean the tube.accelerate in spite side.of opening throttle •Fuel passage or pulse passage •Disassemble and clean thevalve. of fuel pump is clogged. fuel pump.
•Main adjust screw not adjusted •Adjust the screw properly.properly.
•Clogged needle jet. •Disassemble and clean.•Clogged main check valve. •Disassemble and clean the
check valve portion.•Improper height of control lever. •Adjust the control lever
height properly.•Improper position of clip to jet •Insert the clip to the proper
needle. position (2nd stage) of jet needle.•Unstable revolution at high speed •Clogged air filter. •Clean the filter.
•Dust clogging in or air entering •Remove and clean or replacefuel tube. the tube.
•Air entering engine through the •Retighten the fitting bolts offitting portion of carburetor. the carburetor, or replace the
fitting gasket.•Fuel passage or pulse passage •Disassemble and clean the
of fuel pump is clogged. fuel pump.•Main adjust screw not adjusted •Adjust the screw properly.
properly.•Clogged needle jet. •Disassemble and clean.•Clogged main check valve. •Disassemble and clean the
check valve portion.•Improper height of control lever. •Adjust the control lever
height properly.•When throttle valve is •Air entering engine through the •Retighten the fitting bolts or
returned to idling position, fitting portion of carburetor. replace the fitting gasket.engine stops. •Too low idling revolution. •Adjust the opening of throttle
valve at idling with throttlestop screw.
•Clogged main check valve. •Disassemble and clean thecheck valve portion.
•Clogged needle jet. •Disassemble and clean.•Improper position of clip to jet •Insert the clip to the proper
needle. position (2nd stage) of jet needle.•Worn jet needle or needle jet •Change the clip to upper
position of jet needle. If notgood, replace the jet needleand the carburetor body.
•Improper height of control lever. •Adjust the control leverheight properly.
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5-18 SUPPLEMENTSpark Arrester — KBL23A/KB 26A/KB 34A for US only
KBL23A/KB 26A/KB 34A for US only are equipped with a mufflerin which a spark arrester is installed.
Clean the net of the spark arrester every 50 hours of operationaccording to the following manner.
Removal
Do not attempt to service a hot exhaust muffler or severe burnscould result. Always allow the exhaust muffler to cool prior toservice.
• Unscrew a muffler cover mounting screw (A) to remove the plasticmuffler cover (B) together with a guard (C).
CAUTION
Do not remove the guard (C) unless it is necessary as a tappingscrew (K) has gnawed at the plastic muffler cover (B).
• Unscrew the muffler mounting screws (D) to remove the mufflerassembly (M) out of the engine together with a gasket (E).
• Unscrew a tapping screw (F) to pull the cap (G) out of the exhaustoutlet together with the gasket (H).
• Draw the net (J) of the arrester out of the muffler assembly (M) throughthe exhaust outlet.
Installation• Installation is the reverse of removal.
CAUTION
Do not reuse the gaskets (E and H) and the tapping screw (F).
Cleaning
Do not use gasoline or low flash-point solvents for cleaningpurposes. A fire or explosion could result.
• Clean the net (J) of the arrester by soaking it in a high flash-pointsolvent and dry with compressed air.
• If the net (J) of the arrester is still clogged after soaking, gently cleanit with a fine wire blush in the solvent and dry with compressed air.
• Reinstall the net (J) of the arrester.
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
